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PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
PROGRAMMABLE LOGIC CONTROLLERS
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PROGRAMMABLE LOGIC CONTROLLERS

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  1. Workshop on “PLC Basics & Programming” Prepared by- Rahul N Deshmukh Asst Professor E&TC Dept
  2. Content- • History • Basics of Programmable Logic Controller (PLC) • PLC hardware & software • Inputs/Outputs • PLC Programming Languages • What is an Automation? • Supervisory Control & Data Acquisition System (SCADA) Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  3. History- In 1968, a group of engineers from General Motors developed the concept of PLC with an initial specification. The PLC must be: i . Easy to program. ii. Not need rewiring the control system if change the program. iii. Smaller in size, cheaper and high reliability. iv. simple construction and low maintenance v. Cost- competitive Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  4. Development - • Manual • Contactor & relay based • Logic gates • Microcontroller based • Programmable Logic Controllers • Touchscreen & Wireless PLC’s Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  5. Advantages of PLC- • Less wiring. • Wiring between devices and relay contacts are done in the PLC program. • Easier and faster to make changes. • Trouble shooting aids make programming easier and reduce downtime. • Reliable components make these likely to operate for years before failure. Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  6. PLC Size- • 1. SMALL - it covers units with up to 128 I/O’s and memories up to 2 Kbytes. - these PLC’s are capable of providing simple to advance levels or machine controls. • 2. MEDIUM - have up to 2048 I/O’s and memories up to 32 Kbytes. • 3. LARGE - the most sophisticated units of the PLC family. They have up to 8192 I/O’s and memories up to 750 Kbytes. - can control individual production processes or entire plant. Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  7. Applications- • Manufacturing / Machining • Food / Beverage • Metals • Power • Mining • Petrochemical / Chemical Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  8. Programmable Logic Controller
  9. CPU The Basic Block Inputs Outputs What is PLC? Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  10. What is PLC? Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  11. PLC Construction- Compact PLC Modular PLC Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  12. Some PLC’s- • 80% market is covered by Siemens PLC • Modicon is a first PLC invented in france • Messung & Delta are India made PLC’s Allen Bradley Siemens Modicon Mitsubishi Schneider Electric Messung Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  13. Block Diagram of PLC- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon PROCESSOR POWER SUPPLY I M N O P D U U T L E O M U O T D P U U L T E PROGRAMMING DEVICE From SENSORS Pushbuttons, contacts, limit switches, etc. To OUTPUT Solenoids, contactors, alarms etc.
  14. Functional Interaction of PLC system- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  15. Rack & Rail System in PLC- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  16. What is PLC? Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon network digital inputs digital outputs analog inputs / outputs
  17. Siemens S7-200 PLC Configuration- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  18. Siemens S7-200 CPU- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  19. Siemens PLC expansion Module- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  20. Siemens PLC Status Indicator- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  21. Siemens PLC CPU Internal Circuitry- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  22. Digital Input Circuitry- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  23. Physical Wiring Input Side- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon AC input module DC input module
  24. DC Inputs (Source/Sink)- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon Sinking input module/sourcing input device Sourcing input module/sinking input device
  25. Digital Outputs- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  26. Digital Output Logic- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  27. Physical wiring Output Side- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  28. Analog Input- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  29. Physical Wiring PLC analog Input- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  30. Analog Input example- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  31. Analog Output- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  32. Physical Wiring PLC analog Output- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  33. Analog Output example- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  34. • Switches and Pushbuttons • Sensing Devices • Limit Switches • Photoelectric Sensors • Proximity Sensors • Condition Sensors • Pressure Switches • Level Switches • Temperature Switches • Vacuum Switches • Float Switches • Encoders What are inputs? Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  35. • Valves • Motor Starters • Solenoids • Actuators • Control Relays • Horns & Alarms • Stack Lights • Fans • Counter/Totalizer • Pumps • Printers What are outputs? Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  36. Contactor & Relay- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon Contactor Relay
  37. Input Connection- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  38. Input Connection- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  39. Output Connection- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  40. Output Connection- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  41. PLC Scan Cycle- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  42. PLC Manufacturers
  43. Allen Bradley PLC (America) Siemens PLC (Germany) Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  44. Modicon PLC (France) Crouzet PLC GE Fanuc (Japan & America) Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  45. • Delta PLC (India) • Messung PLC (India) • Mitsubishi (Japan) Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  46. PLC Hardwire System
  47. Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon S1 S2 K1 S1 S2 PLC K1 Hardwire PLC 0 V 24 VDC K1 L N
  48. S7-300 PLC Wiring Diagram Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  49. PLC Programming Languages
  50. Types of Programming Software Languages • Ladder Logic (LL) • IEC Format • Function Block Diagram (FBD) • Structured Text (ST) • Instruction List (IL) • Ladder Diagram (LD) • Sequential Function Chart (SFC) - also known as “Grafcet” Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  51. Ladder Logic Read / Conditional Instructions Write / Control Instructions | | |/| | | |/| | | | | |/| ( ) | | | | Start (Rung #1) End (Rung #4) ( ) ( ) ( ) Inputs Outputs Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  52. Siemens S7-200 I/O Configuration- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  53. Addressing System Input & Output- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon Input- Output-
  54. Function Block Diagram (FBD) Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  55. Structured Text (ST) Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  56. Instruction List (IL) Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  57. Ladder Diagram (LD) Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  58. Sequential Function Chart (SFC) Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  59. PLC Software View Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  60. PLC Program example- eg- Lamp Glows when input switch is activated Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  61. PLC Program example- eg- Lamp Glows when input switch is activated Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  62. PLC Program example- eg- to start & stop the motor Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  63. PLC Program example- eg- to stat the motor Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  64. Latching Condition- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  65. PLC Programming (Siemens S7-300)
  66. Hardware-Siemens S7-300 Software-Simatic Manager -80% market occupied by Siemens -STEP-5 & STEP-7 available with Siemens -I/O Capacity (S7-200 )-32 analog & 256 digital (S7-300)-256 analog & 1024 digital (S7-400)-1500 analog & 128000 digital Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  67. Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  68. Hardware-Siemens S7-300 Software-Simatic Manager Steps for creating programming window (OB-Organization Block) -Install Simatic Manager V-5.5 Software -for (Simulation) install PLCSim v-5.1 Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  69. Addressing System for S7-300 Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  70. What is an Automation?
  71. • Automation is a delegation of human control to the machine • For e.g- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  72. PLC Implementation- Rahul N Deshmukh E&TC Dept SSBT's COET Bambhori Jalgaon
  73. Thank you

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